Apparatus for making and coating egg yolks and other articles

ABSTRACT

Methods and apparatuses are disclosed for coating egg-yolk disks containing egg-yolk materials. The egg-yolk is initially produced in the form of a cylinder, which is cut into disks, which disks after being encapsulated into an edible membrane, are used in combination with egg-white to form egg-products which may be fried or poached in a similar manner as real eggs. The methods and apparatuses of the present invention are useful for coating articles other than egg yolk disks.

This is a Division of application Ser. No. 08/403,424 filed on Mar. 14,1995, now U.S. Pat. No. 5,589,208.

FIELD OF THE INVENTION

This invention relates to methods and apparatuses for making, cuttinginto disks, and coating articles and especially artificial egg-yolkdisks with a restrictive barrier or membrane.

BACKGROUND OF THE INVENTION

Although eggs represent an outstanding nutritional food which is enjoyedby many people, especially as part of one's breakfast, the fact is thatnatural egg yolk is one of the richest foods in cholesterol. This hasforced a large number of people who are on cholesterol and fat freediets from enjoying eating natural whole eggs. One practical andeconomically feasible solution has been to incorporate a simulated andpreferably a cholesterol free egg yolk into natural egg white and topreserve them in separate phases, so that one can make, for example, a"sunny side up" and "over easy" egg. In this regard, there is known inthe inventor's U.S. Pat. No. 5,073,399, which is incorporated byreference herein, a simulated egg yolk and simulated raw whole eggmanufactured therewith constituting an edible liquid, a viscositymodifier which is preferably a positive thermoreversible gel former, anda colorant. The simulated egg yolks produced thereby, which may beencapsulated by a hydrocolloid restrictive barrier, are remarkablylifelike and are useful in the preparation of "sunny side up" and "overeasy" eggs when disposed in natural egg whites.

The inventor realized that in the preparation of a simulated whole rawegg for use in the production of a natural looking "sunny side up" or"over easy" egg, it is typically necessary to store the simulated eggyolk in a separate gelled phase within liquid natural egg white. It wasobserved that these simulated egg yolks tend to absorb water from thenatural egg White, probably by osmosis, thereby undesirably increasingthe weight and volume of the egg yolk. The absorption of water isundesirable because it decreases the viscosity of the egg yolk uponcooking, which adversely results in the reduction of the egg yolk'soverall mechanical and/or physical strength, i.e., the ability to remainunbroken and to retain its integrity and shape prior to beingpurposefully broken after cooking when being eaten. The decrease inviscosity can result in the premature disruption of the structure of thediscrete egg yolk when in the molten state, such as during cooking, anduncontrolled running of the egg yolk at serving temperatures may takeplace. In addition, the reduction in the egg yolk's mechanical and/orphysical strength requires that the egg yolk be handled delicately.

In the inventor's U.S. Pat. No. 5,151,293, which is also herebyincorporated by reference, a number of possible remedies to overcomethese problems of water absorption were proposed. It was observed thatthe positive thermoreversible gel former used in the production of thesimulated egg yolk appeared to be the driving force behind theabsorption of water from natural egg white. Although it was proposed tominimize the amount of gel former used, this also had the tendency ofproducing "delicate" egg yolks whose viscosity will change prematurelysuch that the egg yolk's monolithic structure is lost duringmanufacturing and/or handling, including during cooking. Thus, theproposed solution created other problems which were not fully resolved.

Another proposed method of reducing the initial weight gain of asimulated egg yolk, yet maintaining its viscosity and mechanical and/orphysical strength, is by the use of a restrictive barrier. Severalmethods of imparting such a barrier to the egg yolk before being addedto liquid natural egg white are described, such as a cross-linkedmembrane of an edible resin, e.g. an alginate, a pectin, and the like. Amultivalent cation, such as calcium or aluminum in the form of a saltmay be used as the cross-linking agent. A restrictive barrier can alsobe formed from hydrateable edible polymeric compounds or hydrocolloidswhich give rise to substantial instantaneous increase in viscosity assoon as they come into contact with and start dissolving in aqueoussystems.

Also disclosed is reducing the absorption of water by adding a solute tothe liquid egg white such that smaller osmotic pressure differentialwill exist between the liquid egg white and the simulated egg yolk. Thisis expected to minimize the force thought to be driving water into theegg yolk. Finally, the inventor proposed immersing the egg yolk in anaqueous medium which provides an accelerated tendency of the egg yolk toabsorb water. In this technique, the egg yolk is formulated with lesswater than would otherwise be used. The egg yolk is then immersed intowater until the degree of water absorption desirable has been achieved.When added to liquid egg white, the thus created egg yolk does notexhibit a strong tendency to further absorb water.

Although the '293 patent mentions forming a restrictive barrier layerfrom a cross-linked film of an edible resin, there is no reference to aparticular method of forming the barrier around an egg yolk. The methodsused so far to produce restrictive barriers around simulated egg yolkswere both time consuming and cumbersome. For example, Forkner, U.S. Pat.No. 4,409,249, discusses briefly the use of cross-linked hydrocolloids,such as alginates, with calcium salts, as edible membranes aroundartificial liquid yolks to hold the shape of the egg yolk. Cox et al.,U.S. Pat. No. 5,192,566, discloses various detailed methods of forming arestrictive barrier around a simulated liquid egg yolk. In both Forknerand Cox et al. frozen or otherwise immobilized liquid egg yolk is coatedwith a restrictive barrier forming solution or dispersion such as onecontaining edible hydrocolloids, for example, sodium alginate. Thecoated egg yolk is treated to form the restrictive barrier by contactwith a reactive composition in the form of a setting bath containing asetting agent, for example, calcium chloride. Cox et al. discusses twoalternative methods, the first of which they co-extrude a central yolkportion with a surrounding portion containing the film former, and inthe second they include the film former in the formulation of the yolk.In the preferred method of Cox et al., the second method, therestrictive barrier forming compounds are mixed with the egg yolkcomponents in sufficient quantities to form a barrier on the outersurface of the egg yolk when contacted with a setting agent. The liquidegg yolk is extruded in the form of discrete liquid globules into asetting bath. These methods are undesirably time consuming, requiringthe yolks to stay in the setting bath for 8-15 minutes, followed byrinsing for about 10-20 minutes.

This conventional process of forming a restrictive barrier in accordancewith either Cox et al. or Forkner was found to present a large number ofdisadvantages resulting in a simulated egg yolk having a poorly formedbarrier. A major drawback is the commercially undesirable (which maycome to the point of being unacceptable) length of time needed tocomplete the process. When attempting to use reasonably short times forthe conventional process, additional drawbacks, just to mention a few,include, but are not limited to, irreproducibility of the quality of themembrane, thickness variability, openings in the membrane structure,weak regions which may break easily, and tough to chew regions makingthe consumption of the respective egg unpleasant.

More particularly, the coating of the egg yolk first with a restrictivebarrier forming compound often results in a barrier which is not onlyflimsy, but also not uniform in thickness. When immersed in the settingbath, the restrictive barrier forming compound often does not cross-linkuniformly, in particular, in those regions having a thicker layer,thereby requiring extended residence times. In addition, it has beenfound that in those regions where an excess of restrictive barrierforming compound is present, incomplete cross-linking may still occur,resulting in the barrier layer being relatively weak, and in fact, maybe in the nature of a loose slurry. These regions are potential defectsites which can cause the simulated egg yolk to prematurely ruptureduring handling.

The setting bath which contains the setting agent, for example, calciumchloride being the major representative of setting agent, even at smallconcentrations is known to have a bitter taste. Any excess setting agentwhich is retained on the egg yolk will subsequently dissolve in theliquid egg whites into which the egg yolk is deposited. This will resultin the finally cooked whole egg having a bitter unpleasant taste whichis unacceptable to the consumer. To avoid this problem, it becomesnecessary to subsequently subject the egg yolk to an extensive rinsebath which is highly undesirable from the standpoint of both processtime and economy.

A further disadvantage is the high probability of a remaining slipperyfluid region under the membrane and surrounding the solid at roomtemperature yolk portion, which fluid region consists of unset orincompletely set film former. All these disadvantages render theseprocesses very delicate, sensitive to unforeseen external parameters,time Consuming, and cumbersome. Still more particularly, according tothe conventional method, the yolk is dipped into a solution of a filmformer, which is very viscous even at low concentrations of film former,and therefore it produces an uneven thick film on the yolk. When thisfilm comes in contact with the solution of the setting agent, a thincross-linked skin is formed at the top of the film, away from the yolk.The skin does not allow easy access to the rest of the trapped filmformer, and thus, one has to wait for a long time (many minutes) for thesetting agent, for example calcium ions, to diffuse through the skin andcontinue setting the rest of the resin. This increases the thickness ofthe skin and makes the diffusion process more and more difficult. If onedoes not wait for all the time required to complete the settingthroughout the thickness of the film, there will remain a slippery fluidregion under the skin, adjacent to the yolk, rendering the thus far mademembrane flimsy and not supported by the non-flowable yolk. Further,since the outermost skin of the membrane will be fully cross-linked, dueto the abundance of setting agent in that region, its adhesion to thewhite will be minimal, if any at all, upon cooking the yolk andcoagulating the white. It is a very well known fact that fullycross-linked surfaces are notorious for refusing to adhere to othersurfaces, and they may even be used as release structures. Thus, specialtreatment will be needed to provide adhesion of the membrane to thewhite.

Since the environment at which the membrane was formed in this caseincludes an abundance of setting agent, thorough rinsing becomesnecessary in order to remove the setting agent (calcium chloride, forexample) before the processed yolk is introduced into the egg white. Thetask of removing the setting agent becomes even more difficult, due tothe fact that the portion of setting agent which has been trapped withinthe fully cross-linked outer part of the membrane, and which travelsoutward at a very low speed, does not find any uncross-linked sites tobe bound, and therefore it has to be substantially removed completely toavoid the undesirable taste and other ailments that may introduce to thewhite.

Neither of the aforementioned patents provide a commercially feasiblemethod of manufacturing large quantities of high quality simulated eggyolk and "friable" (either "sunny side up" or "over easy") or"poachable" whole eggs. In the case of U.S. Pat. No. 5,151,293, theproblems of commercializable methods are complicated by attempting tobalance the complexities of water absorption and the need for a strong,monolithic simulated egg yolk with a highly controlledtemperature/viscosity profile (yolk formulated to only become runny andlose its shape when desired).

These problems were solved in Applicant's co-pending application Ser.No. 08/075,106 filed Jun. 11, 1993 which is also incorporated herein byreference, by the provision of a commercially feasible mass productionmethod for the formation of high quality simulated egg yolk which isextrudable at or below room temperature in accordance with the presentinvention. The resulting simulated egg yolk, when added to liquidnatural egg white and, thereafter, fried, yields a realistic egg inflavor, texture and look. The resulting egg retains a discrete egg yolk,even at serving temperatures, which naturally runs upon being disturbed.Thus, the resulting egg product looks, tastes and behaves as a naturalfried or poached egg. Applicant discloses in U.S. Pat. No. 5,401,525,issued on Mar. 28, 1995, which is incorporated herein by reference, anapparatus and method of performing coating of the yolks. However, thedisclosed method of coating yolk disks involves many moving pads, whichadd complexity.

SUMMARY OF THE INVENTION

This invention relates to methods and apparatuses for making and coatingartificial egg-yolk disks or other articles with a restrictive barrieror membrane, as well as eggs containing the coated egg-yolks. Three ofthe most important stations to achieve this are (a) a yolk cylinderstation, wherein the raw material are mixed, processed, and extrudedinto a form of a cylinder, (b) a disk cutting station, wherein the yolkcylinder is cut into disks, as it is being extruded, and (c) a coatingstation, wherein the disks are encapsulated in a membrane, preferablymade of an alginate cross linked with a multivalent ion, such ascalcium, magnesium, and aluminum, for example.

Regarding the yolk cylinder station, this invention relates to a methodof making artificial egg-yolk comprising the steps of:

(a) mixing artificial egg-yolk materials including a positivethermoreversible gel former to form a first mixture, the positivethermoreversible gel former providing a gel temperature to theartificial egg-yolk;

(b) heating the first mixture to a first temperature higher than 140°F.;

(c) mixing a first quantity of the first mixture with a second quantityof a liquid having a second temperature and comprising egg-white to forma second mixture having a third temperature, the first and secondquantities and the first and second temperatures being such that thethird temperature is higher than the gel temperature but lower than atemperature at which the egg-white coagulates.

It is preferable that the first temperature is in the range of 150°-190°F., the second temperature is in the range of 32° to 60° F., and thatthe third temperature is in the range of 100° to 130° F.

It is also preferred that the mixing of the first mixture with theliquid is performed in a static mixer.

This method may also comprise a step of holding part of the secondmixture in a controlled volume vessel at a temperature higher than thegel temperature, and an additional step of further cooling the secondmixture to a temperature under the gel temperature in a manner to gelthermoreversibly said second mixture. The method may also comprise astep of extruding the thermoreversibly gelled second mixture through adie in the form of a cylinder which may be cut into disks. The die maybe selected from the group consisting of a single branched die and amulti-branched die comprising equidistant branches.

This invention also relates to a device for making artificial egg-yolkcomprising:

a first vessel for holding a first mixture of artificial egg-yolkmaterials at a first temperature higher than 140° F., the egg-yolkmaterials comprising a positive thermoreversible gel former, thepositive thermoreversible gel former providing a gel temperature to theartificial egg-yolk;

a second vessel for holding a liquid comprising egg-white at a secondtemperature;

a first pump connected to the first vessel and a second pump connectedto the second vessel,

the first and second pumps being adapted to bring together a firstquantity of the first mixture with a second quantity of the liquid toform a second mixture having a third temperature, the quantities andtemperatures of the first mixture and the liquid being such that thethird temperature is higher than the gel temperature but lower than atemperature at which the egg-white coagulates.

As aforementioned, the first temperature is preferably in the range of150°-190° F., the second temperature is in the range of 32° to 60° F.and the third temperature is in the range of 100° to 130° F.

The device may comprise a static mixer at a point after the firstquantity of the first mixture and the second quantity of the liquid arebrought together to form the second mixture, in order to ensure intimatemixing between said first mixture and liquid. It may further comprise acontrolled volume vessel at a point after the first quantity of thefirst mixture and the second quantity of the liquid are brought togetherto form the second mixture, adapted to hold a controlled amount of saidsecond mixture at a temperature higher than the gel temperature.Preferably, the controlled volume vessel further comprises a levelswitch which is adapted to deactivate the first and second pumps whenthe second mixture exceeds a predetermined high level, and reactivatethe first and second pumps when the second mixture goes under a lowpredetermined level.

The device may also comprise a cooler having a front end and a back end,the cooler being adapted to cool the second mixture to a temperatureunder the gel temperature in a manner to gel thermoreversibly saidsecond mixture. It may further comprise a third pump between thecontrolled volume vessel and the cooler, adapted to advance the secondmixture from the controlled volume vessel to and through the cooler fromthe front end toward the back end at a predetermined rate.

It may also comprise a die connected to the back end of the cooler,which die may be selected from the group consisting of a single brancheddie and a multi-branched die comprising equidistant branches.

Regarding the disk cutting station, this invention pertains to aRegarding the yolk cylinder station, this invention relates to a cuttingdevice for forming egg-yolk disks comprising in combination:

an assembly of a cutting wire and a frame supporting the cutting wire,the cutting wire being adapted to follow a cutting path, the cuttingpath having a first direction; and

an extrusion array comprising

a main cylinder having a front end with a first set of threads; and

an extrusion head having a front surface and a second set of threadscommensurate to the first set of threads of the main cylinder, in amanner that the extrusion head may be threaded on the main cylinder to adesired degree in order to attain a desired position, wherein the frontsurface substantially coincides with the cutting path of the cuttingwire, so that when the cutting wire follows the cutting path, saidcutting wire slides on the front surface of the extrusion head.

The cutting device for forming egg-yolk disks of the instant inventionmay also comprise in combination:

an assembly of a cutting wire and a frame supporting the cutting wire,the cutting wire being adapted to follow a cutting path, the cuttingpath having a first direction;

an extrusion die having a front surface substantially coinciding withthe cutting path of the cutting wire, so that when the cutting wirefollows the cutting path, said cutting wire slides on the front surfaceof the extrusion die.

It is preferable that the extrusion head has rounded edges in order toignore accidental misalignment of the front surface with respect to thecutting path. It is also preferable that it comprises a mechanismadapted to lock the extrusion head in position, which locking mechanismmore preferably comprises a nut having a third set of threadscommensurate to the first set of threads.

The diameter of the wire is preferably between 1/64" and 3/32", and thedevice preferably comprises a liquid dispenser for providing wettingliquid to wet the cutting wire.

It is further preferable that

the frame has a low point and a high point

the cutting wire extends from the low point to the high point in asecond direction deviating from horizontal,

the first direction of the cutting path is substantially vertical, and

the liquid dispenser is adapted to provide the wetting liquid at thehigh point so that the wetting liquid runs downhill on the cutting wire,thereby wetting the cutting wire.

The liquid dispenser may also provide wetting liquid on top of theextrusion array to wet the cutting wire as the cutting wire startscutting extruded yolk. The liquid dispenser may also provide wettingliquid to the cutting wire by spraying. The cutting wire itself may playthe role of the liquid dispenser by being porous and adapted to exudewetting liquid through pores.

The disk coating station of the instant invention pertains to a methodof encapsulating an article with a restrictive barrier comprising thesteps of:

(a) contacting the article with an excess of a first liquid containing afirst reactant;

(b) separating the article from the excess of the first liquid;

(c) subsequently treating the wetted article with an excess of a secondliquid containing a second reactant, which second reactant reacts withthe first reactant to form the restrictive barrier; and

(d) separating the treated article from the second liquid;

with the requirement that at least one of the separating steps (b) and(d) is performed in the absence of mechanically moving parts.

It is preferable that both of the separating steps are performed in theabsence of mechanically moving parts.

It is also preferable that the first reactant comprises a cross-linker,and the second reactant comprises a cross-linkable polymer, and thearticle is a yolk disk. It is further preferable that the cross-linkercomprises a multivalent ion selected from a group consisting of calcium,magnesium, aluminum, and a mixture thereof, and the cross-linkablepolymer comprises an alginate.

It is preferred that at least one of the separating steps (b) and (d)further comprises at least one step of sliding the wetted or treatedarticle on a sliding plate, the sliding plate having a lower curvatureand a direction, in a manner that said article follows a first path awayfrom the curvature in an initial direction substantially parallel to thedirection of the sliding plate, while at least part of the liquidfollows a second path at least partially coinciding with the curvature.It is also preferred that the sliding plate has a first surface tensionand an inclination, and the liquid has a second surface tension, thefirst surface tension being higher than the second surface tensionthereby causing the liquid to follow the second path, and wherein theinclination is adequately high to cause the article to follow the firstpath.

It is further preferred that at least one of the separating steps (b)and (d) further comprises a step of blowing a gas on the slidingarticle.

At least one of steps (a) and (c) may comprise a step of wetting thearticle with the liquid, the liquid being at least partially in a formselected from a group consisting of (i) a stream moving in asubstantially upward direction, (ii) a stream moving in a substantiallyhorizontal direction, (iii) a turbulent stream with an inclined flowdirection, and (iv) a liquid curtain.

In a preferable combination:

step (a) comprises a sub-step of passing the article through a curtainof the first liquid in a manner to be wetted by the first liquid;

steps (b) and (d) each comprises at least one sub-step of sliding thewetted article on a sliding plate, the sliding plate having a lowercurvature and a direction, in a manner that said article follows a firstpath away from the curvature in an initial direction substantiallyparallel to the direction of the sliding plate, while at least part ofthe liquid follows a second path at least partially coinciding with thecurvature;

step (b) also comprises a sub-step of blowing a gas on the slidingarticle;

step (c) comprises a sub-step of disposing the article into a stream ofthe second liquid moving in a substantially horizontal direction and asub-step of passing the article through a curtain of the second liquid;and preferably

step (d) further comprises a sub-step of blowing a gas on the slidingarticle.

The methods of this invention may further comprise subsequent steps of

(e) disposing the article into a stream of rinsing water moving in asubstantially horizontal direction and a sub-step of passing the articlethrough a curtain of the rinsing water; and

(f) sliding the rinsed article on a sliding plate, the sliding platehaving a lower curvature and a direction, in a manner that said articlefollows a first path away from the curvature in an initial directionsubstantially parallel to the direction of the sliding plate, while atleast part of the water follows a second path at least partiallycoinciding with the curvature.

This invention also pertains to a method of separating an article,preferably a yolk disk, wetted with a liquid from an excess of theliquid, the method comprising a step of sliding the wetted article on asliding plate, the sliding plate having a lower curvature and adirection, in a manner that said article follows a first path away fromthe curvature in an initial direction substantially parallel to thedirection of the sliding plate, while at least part of the liquidfollows a second path at least partially coinciding with the curvature,wherein preferably the sliding plate has a first surface tension and aninclination, and the liquid has a second surface tension, the firstsurface tension being higher than the second surface tension therebycausing the liquid to follow the second path, and wherein theinclination is adequately high to cause the article to follow the firstpath.

The coating station of this invention also pertains to an apparatus forencapsulating an article, preferably a yolk disk, with a restrictivebarrier comprising:

(a) a first liquid wetting station adapted to contact the article withan excess of a first liquid containing a first reactant;

(b) a first separator adapted to separate the article from the excess ofthe first liquid;

(c) a second liquid wetting station adapted to treat the wetted articlewith an excess of a second liquid containing a second reactant, whichsecond reactant reacts with the first reactant to form the restrictivebarrier; and

(d) a second separator adapted to separate the treated article from thesecond liquid.;

with the requirement that at least one of the first and secondseparators is free of mechanically moving parts.

Preferably:

both the first and second separators are free of mechanically movingparts,

the first reactant comprises a cross-linker, and the second reactantcomprises a cross-linkable polymer,

the cross-linker comprises a multivalent ion selected from a groupconsisting of calcium, magnesium, aluminum, and a mixture thereof, andthe cross-linkable polymer comprises an alginate.

Preferably, at least one of the first and second separators furthercomprises at least one sliding plate, the sliding plate having a lowercurvature and a direction, in a manner that said article, when disposedon the sliding plate, follows a first path away from the curvature in aninitial direction substantially parallel to the direction of the slidingplate, while at least part of the liquid follows a second path at leastpartially coinciding with the curvature. More preferably, the slidingplate has a first surface tension and an inclination, and the liquid hasa second surface tension, the first surface tension being higher thanthe second surface tension thereby causing the liquid to follow thesecond path, and wherein the inclination is adequately high to cause thearticle to follow the first path. Also, preferably, at least one of theseparators (b) and (d) further comprises a gas blower for blowing gas onthe article.

Further, it is preferable that at least one of the first and secondliquid wetting stations (a) and (c) comprises a liquid dispenseradaptable to provide the respective liquid at least partially in a formselected from a group consisting of (i) a stream moving in asubstantially upward direction, (ii) a stream moving in a substantiallyhorizontal direction, (iii) a turbulent stream with an inclined flowdirection, and (iv) a liquid curtain. It is more preferable that atleast one of the first and second liquid wetting stations (a) and (c)further comprises a liquid curtain generator.

In a different preferred assembly:

the first wetting station (a) comprises a first liquid curtain generatorfor producing a curtain of the first liquid in order to wet the article;

the first and second separators, each comprises at least one slidingplate, the sliding plate having a lower curvature and a direction, in amanner that said article follows a first path away from the curvature inan initial direction substantially parallel to the direction of thesliding plate, while at least part of the liquid follows a second pathat least partially coinciding with the curvature;

the first separator further comprises a first gas blower for blowing agas on the article; and

the second wetting station comprises

a liquid dispenser adaptable to provide the second liquid in a form of astream moving in a substantially horizontal direction for wetting thearticle, and

a liquid curtain generator positioned in a manner to wet any part of thearticle that might accidently escape wetting from the liquid stream.

The above assembly may further comprise:

(e) a rinsing station comprising

a water dispenser adaptable to provide water at least partially in aform selected from a in a form selected from a group consisting of (i) astream moving in a substantially upward direction, (ii) a stream movingin a substantially horizontal direction, (iii) a turbulent stream withan inclined flow direction, for rinsing the article, and

a water curtain generator positioned in a manner to rinse any part ofthe article that might accidently escape rinsing from the liquid stream;and

(f) a water separator adaptable to separate the water from the article,comprising a sliding plate, the sliding plate having a lower curvatureand a direction, in a manner that said article follows a first path awayfrom the curvature in an initial direction substantially parallel to thedirection of the sliding plate, while at least part of the water followsa second path at least partially coinciding with the curvature.

This invention also pertains an apparatus of separating an articlewetted with a liquid from an excess of the liquid, the device comprisinga step of sliding the wetted article on a sliding plate, the slidingplate having a lower curvature and a direction, in a manner that saidarticle follows a first path away from the curvature in an initialdirection substantially parallel to the direction of the sliding plate,while at least part of the water follows a second path at leastpartially coinciding with the curvature. Preferably, the sliding platehas a first surface tension and an inclination, and the rinsing waterhas a second surface tension, the first surface tension being higherthan the second surface tension thereby causing the water to follow thesecond path, and wherein the inclination is adequately high to cause thearticle to follow the first path.

BRIEF DESCRIPTION OF THE DRAWING

The reader's understanding of this invention will be enhanced byreference to the following detailed description taken in combinationwith the drawing figures, wherein:

FIG. 1 illustrates in a block diagram the miscellaneous stationsrequired for making, packaging and storing artificial yolks and eggsaccording to the present invention.

FIG. 2 illustrates a preferred yolk cylinder station according to thepresent invention.

FIG. 3A illustrates a die in the form of a tube for making a yolkcylinder according to the present invention.

FIG. 3B illustrates a different die having a restricted openingaccording to the present invention.

FIG. 4 illustrates a multi-branched die according to the presentinvention.

FIG. 5 illustrates a highly preferred die according to the presentinvention having an adjustable extrusion head.

FIG. 6A illustrates a cutting wire supported by a frame according to thepresent invention.

FIG. 6B illustrates an inclined cutting wire supported on a frame with afluid dispenser at a high point of the frame according to the presentinvention.

FIG. 6C illustrates a different configuration of a cutting wiresupported by a frame according to the present invention.

FIG. 6D illustrates still a different configuration of a cutting wiresupported by a frame according to the present invention.

FIG. 6E illustrates a porous or perforated cutting wire according to thepresent invention.

FIG. 6F illustrates an arrangement, wherein the fluid dispenser islocated above the extrusion head, and wets the cutting wire indirectly,as the cutting wire cuts a yolk disk according to the present invention.

FIG. 6G illustrates a cutting wire supported by a frame with a fluiddispenser wetting the wire with a spray according to the presentinvention.

FIG. 7 illustrates the initial position of a cutting wire supported by aframe activated by an assembly of two cylinders according to the presentinvention.

FIG. 8 illustrates a position of a cutting wire supported by a frameactivated by an assembly of two cylinders while the wire is cutting ayolk disk according to the present invention.

FIG. 9 illustrates a position of a cutting wire supported by a frameactivated by an assembly of two cylinders after the wire has cut a yolkdisk according to the present invention.

FIG. 10 illustrates a different position of a cutting wire supported bya frame activated by an assembly of two cylinders after the wire has cuta yolk disk according to the present invention.

FIG. 11 illustrates still a different position of a cutting wiresupported by a frame activated by an assembly of two cylinders after thewire has cut a yolk disk according to the present invention.

FIG. 12 illustrates a preferred coating station according to the presentinvention.

FIG. 13 illustrates a first liquid curtain generator according to thepresent invention.

FIG. 14 illustrates a sliding plate according to the present invention.

FIG. 15 illustrates different sliding plate according to the presentinvention.

FIG. 16 illustrates a gas blower according to the present invention.

FIG. 17 illustrates a first corridor according to the present invention.

FIG. 18 illustrates a second liquid curtain generator according to thepresent invention.

FIG. 19 illustrates a different type of a wetting station which producesan upward stream of wetting liquid, combined with a separator, accordingto the present invention.

FIG. 20 is a perspective view of the wetting station of FIG. 19according to the present invention.

FIG. 21 illustrates a different type of a wetting station which producesa turbulent stream of wetting liquid, combined with a separator,according to the present invention.

FIG. 22 is a perspective view of the wetting station of FIG. 21according to the present invention.

FIG. 23 illustrates a mechanism of replenishing consumed wetting liquidsin the tanks of the coating station.

DETAILED DESCRIPTION OF THE INVENTION

As aforementioned, this invention relates to methods and apparatuses formaking and coating artificial egg-yolk disks or other articles with arestrictive barrier or membrane, as well as eggs containing the coatedegg-yolks.

Referring now to FIG. 1, there is depicted a block diagram illustratingan assembly 10 of miscellaneous operating stations preferably used forthe production of egg-yolks and eggs according to this invention.

In a "Yolk Cylinder Station" 12, different raw materials are mixed andtreated, as it will be described in detail hereinbelow, to produce,preferably by extrusion, a continuous cylinder of egg-yolk having adesired diameter, preferably between 1.25 and 2 inches. As the cylindercomes out of a die, it is cut into disks in a "Disk Cutting Station" 14,having a thickness of preferably 1/8 to 1/2 inch, and more preferably1/4 to 3/8 inch. As the disks are cut, they are disposed in a "DiskCoating Station" 16, where they are coated with a restrictive barrier ormembrane, preferably comprising an alginate, which more preferably iscross-linked with calcium ions. The coated yolk disks are then directedto a "Packaging Station" 18, where they are added along with anappropriate amount of egg-white into containers, preferably inindividual portions of one or two yolks per container with therespective white. The weight ratio of egg-yolk to egg-white ispreferably the same as in real eggs, or about 1:3 to 1:5. In sequence,the packaged eggs may be frozen by passing through a "Freezing Station"20 or placed directly for storage in a "Storage Station" or "StorageFreezer" 22. If the "Freezing Station" is omitted, the eggs are frozenin situ in the storage freezer 22.

In a preferred embodiment of the instant invention, the coating station12 comprises mixing vessel 24 preferably provided with a mixer 26, asbetter shown in FIG. 2. The mixing vessel 24 is connected to acirculation pump 28, which circulation pump communicates in turn with afirst valve 30. The first valve 30 is adapted to open communication atwill,

either between the circulating pump 28 and a first heat exchanger 32,which in turn communicates through line 34 with the mixing vessel 24,

or between the circulating pump 28 and a first holding vessel 36 throughline 38.

The heat exchanger 32 is preferably of the plate or the tubular type,well known in the art. The first holding vessel 36 is preferablythermally insulated (not shown).

Vessel 24 may be jacketed (not shown) for heating, in which case pump 28may by directly connected to line 38. In such a case, valve 30, heatexchanger 32 and line 34 are not necessary.

There are also provided a second holding vessel 40, a first pump 42, anda second pump 44, in a manner that the first pump 42 communicates withthe first holding vessel 36, while the second pump 44 Communicates withthe second holding vessel 40. The pumps 42 and 44 are preferablymetering pumps adapted to merge predetermined amounts of contents fromthe respective holding vessels 36 and 40 into one stream in merge line46. Merge line 46 is preferably connected to a mixer 48, which ispreferably a static mixer. The second holding vessel 40 is preferablythermally insulated (not shown) or even more preferably jacketed (notshown) for circulating cold fluid and keeping its contents cool,preferably between 60° and 32° F.

The mixer 48 is in turn connected to a controlled volume vessel 50,which is provided with a level switch 52. The level switch 52 is adaptedto turn the pumps 42 and 44 off when the contents of the controlledvolume vessel 50 exceed a high predetermined level 54 and turn them onagain when the contents go under a low predetermined level by techniqueswell known to the art. The level switch may be single or a combinationof switches, such as electrical, mechanical, optical, acoustical, andthe like, or a combination thereof, well known in the art of levelswitches. Although in this particular case, the level switch is shown tobe outside the controlled volume vessel 50, it may also be inside thecontrolled volume vessel 50, or both inside and outside.

The controlled volume vessel 50 is connected in sequence to a cooler 58having a front end 60 and a back end 62. The cooler is preferably ascraped surface heat exchanger.

There is also provided a third pump 64 between the controlled volumevessel 50 and the cooler 58, adapted to advance contents from thecontrolled volume vessel 50 to and through the cooler 58 from the frontend 60 toward the back end 62 at a predetermined rate. The back end 62of the cooler 58 is connected through a second valve 66 and line 67 to adie 68, which may be a single die or a multi-branched die, preferablycomprising equidistant branches as better shown in FIG. 4. A single die,for example, may be just a tube having the desired diameter as bettershown in FIG. 3A, or a larger diameter tube 68b with a restrictedopening 70 of the desired diameter for the yolk cylinder, as bettershown in FIG. 3B. Any other configurations are possible, as long as theyprovide the proper opening. A multi-branched die (FIG. 4) preferablycontains an even number of dies which are equidistant from the line 67.By the term "equidistant branches", it is meant that the gelled yolkwill travel substantially the same distance to exit each die as acylinder. This condition is very critical to attain equal rates of yolkcoming out of each die. For example, in FIG. 4, if the dies end at crosssection AA, there are two equidistant branches, if the dies end at crosssection BB, there are four equidistant branches, and if the dies end atCC, there are eight equidistant branches. The same result may beachieved with non-equidistant branches, but restrictive structures,preferably variable valves, have to be connected in the shorter branchesin order to restrict flow and achieve the same rate of cylinder deliveryfrom each die.

The second valve 66 is adapted to interrupt the flow from line 67 anddirect it to a secondary line 69 at will. This is useful especially atthe beginning of a run to ensure proper consistency and other propertiesof the yolk mixture before it enters the die 68, or for any other reasonthat the entrance of egg yolk mixture to the die 68 is undesirable.

All vessels are preferably covered with covers 25 and preferably operatewith blankets of a clean gas (not shown), preferably nitrogen. Othergases, such a carbon dioxide, noble gases, cleaned air by filtration Orother means, gases including air which contain microbial growthinhibitors such as ozone, oxygen anions, and the like for example, mayalso be used. The term "blanket of a gas" means that a small amount ofclean gas is forced to enter the vessel and cause a positive pressureunder the cover and over any contents in the vessel, as compared to theatmospheric pressure outside the vessel, so that the contents of thevessel do not get contaminated from impurities in the environment of thevessel. This is very well known technology in the art, and it is usednot only in the food industry to avoid microbial contamination, but alsoin many other industries, such as the paint industry, for example,mainly to prevent oxygen from entering the system, which could causeexplosions when mixed with vapors of combustible materials contained inthe vessel.

In operation of the yolk cylinder station 12, better shown in FIG. 2,artificial-egg-yolk materials which include a positive thermoreversiblegel former, such as gelatin for example, are mixed in the mixing vessel24 by means of a mixer 26, such as a "lightning" mixer for example, wellknown to the art, or any other type of mixer, or even manually with thehelp of a paddle. Other useful artificial-egg-yolk materials include butare not limited to water, starch, milk, preferably of the non-fat type,colorants, such as beta-carotene or other FDA approved colors forexample, flavorings, and the like. The positive thermoreversible gelformer provides the artificial egg yolk with a gel temperature underwhich the mixture is in the form of a gel, under equilibrium conditions,and over which, the artificial egg yolk is flowable. The gel temperaturewith the preferred positive thermoreversible gel formers is in the rangeof 80° to 100° F.

Preferably, the water is added first in the mixing vessel 24.Preferably, with the circulating pump 28 in an off position, the mixer26 is turned on, and the solid raw materials, preferably after havingbeen premixed together, are added slowly, preferably at roomtemperature. Preferably, when a uniform dispersion or emulsion orsolution, or a combination thereof has been realized in the mixingvessel 24 in the form of a first mixture, the first valve is turned todirect flow toward the heat exchanger 32, and the circulation pump isturned on. The first mixture is heated as it passes through the firstheat exchanger 32 and re-enters the mixing vessel 24 through line 34.The heating and recirculation is continued until the first mixtureattains a desired first temperature. The first temperature should behigher than the temperature required to dissolve the positivethermoreversible gel former, gelatin for example, and to hydrate thestarch, if present, or to uniformly distribute any other ingredientspresent. For sanitary purposes it is critical that the desired firsttemperature is higher than 140° F., which is the temperature ofpasteurizing egg-whites. Preferably, it is in the range of 150° to 190°F., and more preferably in the range of 160° to 180° F. By raising thetemperature at these levels and for periods of time preferably between 5and 60 minutes (including time in the first holding vessel), low or nomicrobial count may be realized.

As aforementioned, the mixing vessel 24 is preferably covered with acover 25, and provided with a blanket of clean gas, well known to theart, to prevent microbial contamination. As also aforementioned, thevalve 30 and the heat exchanger 32 are not necessary if the mixingvessel is jacketed and thus heated with a hot fluid, such as water orsteam for example.

In sequence, the circulation valve 30 is turned in a manner to directflow to the first holding vessel 36 through line 38. The first holdingvessel 36 is preferably thermally insulated by well known to the arttechniques, and also preferably covered with one of covers 25, andblanketed with a clean gas (not shown) as explained previously. Anexcess of first mixture is always in the first holding vessel 36, sothat further uninterrupted operation of the system takes place.

After the first mixture has been transferred to the first holding vessel36, a new first mixture may be prepared in the mixing vessel 24, asalready explained. This way, while the first mixture is made in a batchmode, the process is substantially continuous, as it will be realizedlater in this description.

A liquid comprising egg white, preferably pasteurized egg-white, whichmay contain other ingredients, such as thickeners, flavorings,colorings, and the like is disposed in the second holding vessel 40.This liquid is maintained at a second temperature, preferably between60° and 32° F., and more preferably between 40° and 32° F. Preferablythermal insulation (not shown) outside the second holding vessel or morepreferably a cooling jacket (not shown) maintain the temperature withinthe desired levels.

As aforementioned, the second holding vessel 40 is preferably coveredwith a cover 25, and provided with a blanket of clean gas, well known tothe art, to prevent microbial contamination. It is also preferablycovered with one of covers 25, and blanketed with a clean gas (notshown) as explained previously.

The first mixture from the first holding vessel 36 and the liquid fromthe second holding vessel 40 are caused to merge together in the form ofa second mixture in merge-line 46 by means of the first 42 and thesecond 44 pumps, respectively, in such quantities that the secondmixture attains a third temperature, which is higher than the geltemperature of the egg yolk and lower than a temperature at which theegg-white coagulates under the conditions of the process of the instantinvention. The coagulation temperature depends on time of exposure atthat temperature, but usually is over 130° F. The preferred thirdtemperature range is in the range of 100° to 130° F. The merged streamsof the first mixture and of the liquid comprising egg-white, which formthe second mixture in the merge line 46, are preferably mixed further bymeans of mixer 48, which is preferably a static mixer.

Since positive thermoreversible gel formers, such as gelatin forexample, when used in ample quantities tend to make the yolk absorbwater and swell when the yolk is in contact with liquid egg-white, it ispreferable to use the minimum possible amount of positivethermoreversible gel former in the formulation, which amount, however,is adequate to give enough strength to the gel led yolk to withstand theconditions of the present process.

In turn, the second mixture, being still flowable is introduced into thecontrolled volume vessel 50. The purpose of the controlled volume vessel50 is to provide a continuous source of flowable material which may bepumped with the third pump 64 into the cooler 58, in which it gels bythe time it reaches the back end 62 of the cooler 58. Although the pump64 is preferably a positive displacement pump, it cannot pump gelledartificial yolk, most probably due to cavitation. Thus, it is importantto position the pump at a point where the second mixture is stillflowable, so that it can be pumped and push the gel in front of it to beextruded through the die 68.

The first pump 42 and the second pump 44, preferably work simultaneouslyand are adapted to deliver the respective material in such a ratio thatwill fulfill the above mentioned conditions. A preferred weight ratio isin the range of 75/25 to 50/50 of first mixture from the first holdingvessel 36 to liquid from the second holding vessel 40, provided theabove mentioned conditions are met.

In order to prevent overflow in the controlled volume vessel 50, thelevel switch 52 turns both first and second pumps off when the secondmixture exceeds a predetermined high level 54, and reactivate the firstand second pumps when the second mixture goes under a low predeterminedlevel 56. The first and second pumps 42 and 44 are arranged to deliver aslightly higher quantity of material as compared to the material pumpedby the third pump 64. This way, the turn on and off of the first andsecond pumps is minimized. It should be noted, however, that the firstand second pumps should not be allowed to deliver less material than thematerial pumped by the third pump 64, to prevent the pump 54 fromrunning dry.

The gelled and homogenized yolk exiting the back end 62 of cooler 58,which cooler is preferably a scraped surface heat exchanger asaforementioned, goes through the second valve 66, which initiallydirects the artificial yolk to the secondary line 69 for examination. Ifthe yolk is according to desired specifications, and especially ofdesired gel consistency, the secondary valve 66 is caused to redirectthe flow of the yolk to the die 68 through line 67.

If the die is a single die as shown in FIGS. 3A and 3B, a yolk cylinderstarts being formed having the diameter of the tube 68a or of theopening 70, respectively. If the die is multi-branch die as shown inFIG. 4, a respective multiplicity of cylinders will start being formedat the end of the branches, which are preferably equidistant asexplained and defined earlier. The amount of yolk material coming offeach branch will be about the same.

At this point the disk cutting station 14 (FIG. 1) performs theoperations described hereinbelow.

In the cutting station 14, it is highly preferable that the single die,or each branch of a multi-branched die comprises an extrusion array 72as better shown in FIG. 5. The extrusion array 72 comprises a maincylinder 74 having a front end 76 with a first set of threads 78. Theextrusion array 72 also comprises an extrusion head 80 having a frontsurface 82 and a second set of threads 84 commensurate to the first setof threads 78 of the main cylinder 74. The extrusion head 80 may bethreaded on the main cylinder to a desired degree in order to attain adesired position. At this position, the front surface 82 substantiallycoincides with the cutting path 86 of a cutting wire 88, so that whenthe cutting wire 88 follows the cutting path 86 from point W to point X,the cutting wire 88 slides on the front surface 82 of the extrusion head80, thus cutting the extruded yolk 85 in the form of a disk. Theextrusion head 80 has rounded edges 90 in order to ignore accidentalsmall misalignment of the front surface 82 with respect to the cuttingpath 86. It is preferable that a locking mechanism is adapted to lockthe extrusion head 80 in position. Preferably, the locking mechanismcomprises a nut 92 having a third set of threads 94 commensurate to thefirst set of threads 78. When the extrusion head 80 is in the desiredposition, the nut 92 is turned in a manner to come in close contact withthe extrusion head 80 and lock it at the desired position. It is Veryimportant for the cutting wire 88 to slide on the front surface 82 ofthe extrusion head 80 for a clean and fast cutting of the extruded yolk85.

The cutting wire 88 is supported on a frame 96, and it is adapted toinitially follow the aforementioned cutting path 86 from point W topoint X, and finally the rest part XYZW of a whole loop WXYZW, as itwill be explained in detail hereinbelow. The cutting path has a firstdirection indicated by the arrows from point W to point X. The firstdirection of the cutting path 86 is preferably substantially vertical.

The diameter of the cutting wire 88 is preferably in the range of 1/64'to 3/32', and it is preferable that the cutting wire 88 is being wettedduring the operation of cutting the artificial egg yolk disks.

FIG. 6A better illustrates a cutting wire 88a supported on a frame 96aaccording to the present invention.

Preferably, the frame 96b has a low point 98b and a high point 100b, asbetter shown in FIG. 6B. The cutting wire 88b extends from the low point98b to the high point 100b in a second direction, which second directiondeviates from substantially horizontal, as shown by the arrow H. Thisdeviation is preferably in the range of 3 to 45 degrees, more preferablyin the range of 5 to 30 degrees, and even more preferably in the rangeof 10 to 20 degrees. It is also preferable that the first direction ofthe cutting path is substantially vertical, as shown by the arrow V.

At the higher end 100b, there is located a fluid dispenser 102b, whichis adapted to provide a wetting liquid 104b, preferably comprisingwater, such as tap water or a solution of a cross-linker or settingagent for example, as it will be explained at a later section. As thewetting liquid 104b is dispensed on the cutting wire 88b in the vicinityof the high point 100b, the wetting liquid 104b starts flowing on thecutting wire 88b in a downhill direction from the high point 100b to thelow point 98b, due to a combination of surface tension and gravityphenomena. At the low point 98b the wetting liquid 104b falls downwarddue to gravity. Some excess wetting liquid 104b also falls downward inthe vicinity of the high point 100b. In this way, the cutting wire 88bis maintained wet during the operation of the cutting process.

Wetting of the cutting wire is very important for considerably bettercutting of the egg yolk disks from the egg-yolk cylinder, as it willalso be better described later on.

An alternate way for the cutting wire to be wetted is shown in FIG. 6E,where the cutting wire 88e is hollow and porous. The magnified view ofthe cutting wire 88e shows the pores 89e, through which the wettingliquid exudes to the surface 87e from the core 91e, in which the wettingliquid is under adequate pressure to allow an adequate amount of wettingliquid to maintain the surface 87e of the porous cutting wire 88ewetted. Such porous wires may be made by well known to the arttechniques, such as metal or ceramic sintering for example. Also,plastic tubes, similar to the ones used for underground watering ofplants, but appropriately small in diameter may be used for thispurpose. A fluid dispenser (not shown) connected to the core 91e of theporous wire 88e provides the pressurized wetting liquid as describedabove.

Still another way of maintaining the wire wet is by spraying. Such anarrangement is better shown in FIG. 6G, where the cutting wire 88gsupported by the frame 96g is wetted with the sprayed wetting liquid104g from the fluid dispenser or spray nozzle 102g. It is preferablethat the spray nozzle 102g provides a flat spray pattern pointed in away to wet the wire without excessive overspray.

Instead of attempting to wet the cutting wire directly, the extruded eggyolk 85f may be wetted by a fluid dispenser disposed on top of theextrusion array 72f, as better shown in FIG. 6F. The wetting liquid 104fwets the yolk, but also the cutting wire (not shown) as the cutting wiremoves in a manner discussed above to cut the extruded yolk to a disk.

If the cutting wire 88c is sturdy enough, it may be supported on theframe 96c as illustrated in FIG. 6C. If the cutting wire is even moresturdy it may be in the form of a single prong 88d supported on a frame96d, better shown in FIG. 6D,

In order to perform the appropriate movement for the cutting wire 88(FIG. 5) to follow the path WXYZW, the frame 96 of the cutting wire 88is connected to the stem 106 of a first cylinder 108, which ispreferably air activated, as better shown in FIG. 7. The first cylinder108 is preferably disposed above the extrusion head and pivoted at afirst pivot point 110, away from the stem 106. It is also pivoted at asecond pivot point 112, close to the stem 106. The second pivot point112 is attached to one end of the stem 114 of a second cylinder 116,which is also preferably air activated. The end of cylinder 116 awayfrom stem 114 is pivoted at a third pivot point 118. A number ofmicro-switches, and other controls are not shown for clarity, as beingwell known to the art.

In operation of the disc cutting station 14 (FIG. 1), the extrusion head80 (FIG. 5) is turned until it is in such a position that when the frame96 moves in a downward direction from point W to point X, the cuttingwire 88 slides on the front surface 82 of the extrusion head 80. Bymeans of locking nut 92, the extrusion head is locked in that position.Although, even without the cutting wire 88 coming in contact with thefront surface 82, the system is operable, the quality of the yolk diskscut and the speed at which they can be cut improves highly when thecutting wire 88 comes in contact with or slides on the front surface 82.

As the gelled yolk 85, made in the yolk cylinder station, starts beingextruded from the extrusion cup 80, the cutting arrangement shown inFIGS. 7 to 11 is turned on. The initial position of this system is theone shown in FIG. 7. At this position, the cutting wire 88 is at point W(see also FIG. 5). When the system is turned on, the cylinder 108 isactivated by compressed air, and stem 106 starts expanding in a mannerto start cutting a yolk disk (FIG. 8), until it reaches point X (FIG.9). By that time, a yolk disk 83 has been cut and enters the diskcoating station 16 (FIG. 1), which will be discussed later. When thecutting wire 88 reaches point X, cylinder 116 is activated and stem 114expands to bring to bring the cutting wire 88 to point Y (FIG. 10). Atpoint Y, cylinder 110 is deactivated (or activated in an oppositedirection) so that the stem 106 contracts back to its initial position,and the cutting wire 88 finds itself to point Z (FIG. 11). When thecutting wire 88 reaches point Z, cylinder 116 is deactivated (oractivated in an opposite direction) so that the stem 114 contracts backto its initial position, and the cutting wire 88 finds itself to theinitial point W (FIG. 7), thus completing the loop WXYZW. In sequence,this cycle is repeated until the system is turned off. A number ofswitches, controls, and other auxiliary equipment are not shown sincethey present very well known assemblies to a person of ordinary skill inthe art. In addition, the type of cutting wire or wetting arrangementare not shown, since they have been adequately explained in thedescription of FIGS. 6A to 6G, and they would complicate unnecessarilyFIGS. 7 to 11.

In the case of multi-branched dies, only one cylinder set (twocylinders) may be used to activate the cutting wires of all branches, ifthe branches are equidistant, as aforedescribed. This is a greatadvantage of having equidistant branches.

A preferable rate is about 40 to about 90 cycles or loops per minute,while a most preferable rate is about 50 to 80 cycles or loops perminute.

Depending on the above rate, the third pump 64 (FIG. 2) is controlled topump at such a rate that a desirable thickness of egg yolk disks isproduced. The preferred thickness is in the range of 1/8 to 1/2 inch,and a more preferred thickness is in the range of 1/4 to 3/8 inch.

Conventional electro-optical or other type of detectors, well known tothe art, may be added to detect the thickness of the extruded yolk andactivate the cylinder arrangement every time the yolk reaches adesirable thickness. The cylinder arrangement should then be such as toperform only one cycle or loop every time is activated by the detectors.

The egg-yolk disk 83, after being cut from the yolk cylinder 85 which isextruded from the extrusion head 80 as shown in FIGS. 5 to 11, andparticularly in FIG. 9, enters or falls in the disk coating station 16,as better shown in FIGS. 1 and 12.

The apparatus shown in FIG. 12, and the corresponding coating method maybe used to encapsulate any type of article. However, it is especiallyuseful and critical for coating the egg yolks of the present invention,which yolks before coating are particularly delicate, due to the smallamount of gelatin used in their formulation in order to avoid water pickup when the yolks are stored in liquid egg white. In the followingdiscussion, an exemplary description will be given for encapsulating ayolk disk of the present invention with a restrictive barrier. Howeverit should be understood that a different article may take the place ofthe yolk disk.

The importance of the apparatus and method of the present invention ismainly attributed to the partial or preferably total absence of movingmechanical parts, such as paddles, spoons, scoops, perforated baskets,and the like, for example, in the encapsulation portion of the apparatusand during the encapsulation steps. Fluids are not considered asmechanical parts.

Referring now to FIG. 12, there is provided a first liquid wettingstation 118, which comprises a first liquid curtain generator 120 forproducing a curtain 121 of a first liquid 122, which contains a firstreactant, in order to excessively wet the yolk 83. The first liquidcurtain generator 120, better illustrated in FIG. 13, comprises atubular portion 124 and a flaring portion 126 for producing the curtain121. The first liquid wetting station 118 also comprises a back wall 128for directing the liquid from curtain 121 to a first tank 130, which ispreferably jacketed (not shown) in order to accept cold liquid andmaintain the first liquid 122 cold. The first tank 130 communicatesthrough line 1 31 with the inlet 132 a fourth pump 134, the outlet 136of which is connected to a third valve 138 and a fourth valve 140. Thethird valve 138 and the fourth valve 140 regulate the amount of firstliquid 122 delivered to the first liquid curtain generator 120, as itwill be explained in the section describing the operation of this partof the apparatus. A large strainer 142 on top of line 131 prevents anyyolk disks that might enter accidently the first tank 130 from beingdisintegrated and recirculated through the system.

There is also provided a first separator 144 comprising one or more,preferably 2 to 4, and more preferably three sliding plates 146, such as146a, 146b, and 146c in this particular example (called sliding plates146 collectively). FIG. 14 shows in better detail a sliding plate 146.The sliding plate 146 preferably comprises two side walls 148, a primaryarea an upper end 149, a lower end 151, a curvature at the lower end 151152, an anti-splashing wall 154, and a direction from the upper end 149to the lower end 151, indicated by arrow 156, which is parallel to theinclination of the primary area 150 of the sliding plate 146. Theanti-splashing wall is used to prevent excessive splashing of firstliquid 122 as it falls from the sliding plate(s) 146 to the tank 130.Thus, in the absence of the anti-splashing wall 154, the sliding plate146 would look as shown in FIG. 15.

A gas blower 158, preferably adapted to form a gas curtain, is alsoprovided in front of the sliding plates 146, as shown in FIG. 12. In thecase of using three sliding plates 146a, 146b, and 146c, as in thepresent example, it is preferable that the gas blower 158 is disposed infront of the middle sliding plate 146b, in a preferably substantiallyhorizontal direction. A better detail of a preferred gas blower 158 isillustrated in FIG. 16. The gas blower comprises a flared front part160, which is adapted to form a gas stream in the form of a curtain.

The angle of inclination of the sliding plates 146, or in other wordsthe angle formed by the plane containing the primary area 150 of thesliding plate 146 and the plane containing the surface 123 of the firstliquid 122 should be high enough, so that the yolk 83 or other articlewetted in the first liquid wetting station 118 follows a first path awayfrom the curvature 152 in an initial direction substantially parallel tothe direction of the sliding plate 146 or primary area 150, while atleast part of the liquid 122 follows a second path at least partiallycoinciding with the curvature. The angle of inclination, or inclination,of the sliding plates 146 is preferably in the range of 30 to 70degrees, more preferably in the range of 45 to 70 degrees, and even morepreferably in the range of 50 to 60 degrees. If the angle is smallerthan 30 degrees, the yolk or other article may not slide and stop on oneof the sliding plates 146, while if the angle is larger than 70 degrees,en excessive amount of liquid may start taking the same direction as theinitial direction of the yolk or other article leaving that plate, andin addition, the yolk or other article may start tumbling instead ofsliding.

It is highly preferable that the sliding plate 146 has a first surfacetension and an inclination, and the first liquid 122 has a secondsurface tension, the first surface tension being higher than the secondsurface tension, thereby causing the first liquid 122 to follow thesecond path, and wherein the inclination is adequately high to cause thearticle to follow the first path referred to hereinabove. Ways toincrease the surface tension and wetablility of the sliding plates is toeither flame treat them or sand them by well known to the art techniquesto a point that the first liquid wets them.

The operation of the part of the apparatus 16 described above is asfollows:

With the third valve 138 closed and the second valve 140 open, thefourth pump 134 is turned on. The operator starts opening then the thirdValve 138 slowly until liquid 122 starts appearing at the flaringportion 126 of the first liquid curtain generator 120. At this point theoperator opens further the third valve 138 until a desired amount offirst liquid forms a liquid curtain 121. If more liquid is needed, thefourth valve is closed slowly until the desired amount of liquid isdelivered.

If no liquid appears after complete opening of valve 138, the fourthvalve 140 is closed slowly until liquid appears at the flaring portion126 of the first liquid curtain generator 120. At this point theoperator closes further the fourth valve 140 until a desired amount offirst liquid forms a liquid curtain 121.

Instead of the two valves 138 and 140, one can use a controller forcontrolling the speed of the pump 134, so the appropriate amount ofliquid may be delivered to the liquid curtain generator 120.

The first liquid 122, containing a first reactant, is preferably keptcold in a range of preferably 32° to 60° F., and more preferably 35° to45° F., by circulating a cold liquid through a jacket (not shown) aroundthe first tank 130. However, the temperature might also be at roomlevels around 70° F. or even higher. The low temperatures help inmaintaining the integrity of the gelled yolk, and also inhibitconsiderably microbial growth.

The first reactant preferably comprises a cross linker, which preferablycomprises a multivalent ion selected from a group consisting of calcium,magnesium, aluminum, and a mixture thereof.

As the liquid curtain 121 is formed, a major portion of the liquidpasses through the first opening 125 and follows a path on the back wall128 until it re-enters the first tank 130. Another portion of the firstliquid is diverted onto the sliding plate 146a, and after it follows thecurvature 152a and the anti-splash wall 154, it also re-enters the firsttank 130. At this point, substantially no first liquid is transferred tothe middle sliding plate 146b, or to the final sliding plate 146c.

It should be understood that the distance and exact position of eachplate is easily arranged by the operator, if it has not beenpre-arranged, for receiving optimum results.

When a yolk disk 83 from the disk cutting station 14 (FIG. 1) enters thedisk coating station 16 by falling (FIG. 12) through curtain 121 on thefirst sliding plate 146a, it is wetted excessively by the first liquid122, and it slides until it jumps onto the second sliding plate 146b asit follows a first path away from the curvature 152a in an initialdirection substantially parallel to the direction 156 (FIG. 14) of thesliding plate 146a, while at least part of the liquid 122 follows asecond path at least partially coinciding with the curvature 152a, andthen it follows the anti-splash wall 154a to re-enter the first tank130. As the wetted yolk disk 83 jumps on to the second sliding plate146b, it carries with it a considerable amount of first liquid. Some ofthe first liquid finds itself on the sliding plate 146b substantiallyaway from the yolk disk, and an excess of the first liquid finds itselfon top and periphery of the disk. When the yolk disk passes through thegas curtain 162, the majority of the excess of the first liquid lying ontop and on the periphery of the disk is wiped away, so that when theyolk disk jumps onto the next sliding plate, said yolk disk issubstantially free of excess first liquid, but still well covered by athin continuous layer of first liquid. As it jumps to the third slidingplate 146c, it may carry with it a small amount of first liquid. Theexcess of first liquid onthe second sliding plate 146b and the firstliquid on the third sliding plate 146c follow a similar path on therespective sliding plates as described in the case of sliding plate146a, and finally they re-enter the tank 130.

Finally the yolk disk 83 jumps to a second liquid wetting station 164(FIG. 12) adapted to treat the wetted egg-yolk disk or other articlewith an excess of a second liquid 166 containing a second reactant,which second reactant reacts with the first reactant to form arestrictive barrier encapsulating the egg-yolk disk 83 or other article.In the case that the article is egg-yolk, it is preferable that thesecond reactant is an alginate.

The second wetting station 164 is combined with a second separator 168,which is adapted to separate the egg-yolk disk or other article from thesecond liquid 166.

The second wetting station 164 comprises a first vat 170 whichcommunicates with a substantially horizontal first corridor 172, throughan opening 204 formed by a first flow restrictor plate 174 on top of thefirst vat 170, shown in more detail in FIG. 17. The length of the firstcorridor is preferably in the range of about 1 to about 3 feet. Thesecond wetting station, further comprises a fifth pump 176, adaptable toprovide the second vat 170 with second liquid 166 contained in a secondtank 178, through line 180. There is also provided a second liquidcurtain generator 182, better detailed in FIG. 18. The second liquidcurtain generator 182 comprises a tubular portion 184, and a flaringportion 186. Since the second liquid 166 is of higher viscosity than thefirst liquid 122, the tubular section 184 requires a restricted opening190 formed by a tongue 192, in order to spread the second liquid 166into the form of a good continuous curtain. The degree of restrictiondepends on the viscosity of the second liquid and it may be easilydetermined and optimized by varying the restriction and observing thesecond liquid curtain formed.

The second liquid curtain generator 182 is provided with second liquid166 through line 200 by means of a sixth pump 194 and fifth and sixthvalves 196 and 198, respectively, in the same manner that the firstliquid curtain generator 120 is provided with first liquid 122 throughline 142 by means of fourth pump 134 and third and fourth valves 138 and148, respectively. The second liquid curtain generator 182 is preferablypositioned over the first corridor 172, closer to the first flowrestrictor plate 174 than to the second separator 168.

A large strainer 202 on top of lines 180 and 200 prevents any yolk disksthat might enter accidently the second tank 178 from being disintegratedand recirculated through the system.

The second separator 168 is substantially the same and operates in thesame manner as the first separator 144 described in detail hereinabove.

In operation of the second wetting station 164, the fifth pump 176 isturned on, and the first flow restrictor plate 174 is positioned in sucha location over the first vat 170, so that the liquid stream passingthrough opening 204 is adequately fast to prevent any yolk disks orother articles coming from the first separator 144, from entering thefirst vat 170. It is preferable that a stream 206 of the second liquid166, having a thickness in the range of about 1/4" to about 1", and morepreferably in the range of about 3/8" to about 3/4", is formed in thefirst corridor 172. In sequence the sixth pump is turned on to providethe second liquid curtain generator 182 with an adequate amount ofsecond liquid 166 to generate a second liquid curtain 188 using the sameprocedure used for the first liquid curtain generator 120.

As the yolk disk 83 falls into the second liquid stream 206, in mostcases it is covered completely by second liquid. The second reactant,which is preferably an alginate, such as sodium alginate for example, inthis particular case, reacts with the first reactant (calcium chloridefor example) and forms a continuous restrictive barrier or membraneencapsulating the yolk disk. However, in some occasions, the yolk disk83 instead of being immersed in the stream, it floats. As it passestrough the second liquid curtain 188, it is covered completely withsecond liquid, and the encapsulation process to form a continuousrestrictive barrier takes place. The yolk disk 83 is then carried by thestream over a corridor curvature 208, where the majority of the secondliquid re-enters the second tank 178 after following a path over thecorridor curvature 208 and along the corridor anti-splashing wall 210,while the yolk is further separated from excess of second liquid furtherdown in the second separator 168, the operation of which is the same asthe operation of the first separator 144, and it does not requirefurther explanations.

The second liquid 166, similar to the first liquid 122, is preferablykept cold in a range of preferably 32° to 60° F., and more preferably35° to 45° F., by circulating a cold liquid through a jacket (not shown)around the second tank 178. However, the temperature might also be atroom levels around 70° F. or even higher. The low temperatures help inmaintaining the integrity of the gelled yolk disk, and also inhibitconsiderably microbial growth.

At this point, the encapsulated egg yolk disk may enter the packagingstation 18 (FIG. 1), or it may be rinsed, preferably with water in arinsing station 212.

The rinsing station 212 comprises a second vat 214 which communicateswith a substantially horizontal second corridor 216, through an opening204 formed by a second flow restrictor plate 220 on top of the secondvat 21 4. The length of the first corridor is preferably in the range ofabout 1 to about 3 feet. There is also provided a water curtaingenerator 222, similar to the first liquid generator 120, since theviscosity of water is similar to that of the viscosity of the firstliquid 122. Preferably, fresh water is provided to both the second vat214, and to the water curtain generator 222, while the water after therinsing process, which is temporarily collected in a third tank 224, isdisposed of. A third separator 226 provided after the rinsing station212, is similar to the first and second separators 144 and 168, and needno further explanations.

The operation of the rinsing station and the following third separatorare similar to the operation of the second liquid wetting station andsecond separator, and do not need further explanations. The onlydifference is that in the case of rinsing there are preferably no pumpsfor re-circulation since fresh water is being used and the water afterrinsing is disposed of.

It is preferable that the whole coating station is enclosed in enclosure(not shown) with appropriate openings for an entry and of the uncoatedegg yolk disks and for an exit for the encapsulated egg yolk disks. Itis also preferable that the enclosure is maintained under positivepressure with regard to the environment. The gas provided by the gasblower 158 may be used to produce this positive pressure. If this is notadequate, additional clean gas may also be provided at any location ofthe enclosure, preferably away from the aforementioned entry or exit,and in a manner that the additional gas flow does not interfere with theoperation of the process. By positive pressure in the enclosure, it ismeant that atmospheric air does not enter the enclosure through anyopenings, such as the entry and exit of egg-yolk, for example, due tothe flow of clean gas through such openings in a direction from theinside of the enclosure to the atmosphere. In different words, it ispreferable that the enclosure operates with a blanket of a clean gas(not shown), preferably nitrogen. Other gases, such a carbon dioxide,noble gases, cleaned air by filtration or other means, gases includingair which contain microbial growth inhibitors such as ozone, oxygenanions, and the like for example, may also be used. The term "blanket ofa gas" means that a certain amount of gas is forced to be forced toenter the enclosure and cause a positive pressure as compared to theatmospheric pressure outside the enclosure, so that the contents of theenclosure do not get contaminated from impurities in the environment ofthe enclosure.

A different type of wetting station, than the ones already discussed, isillustrated in FIGS. 19 and 20, according to the present invention. Thiswetting station 228 comprises a tank 230, having attached to it a hollowcylindrical body 232 having an inclined top opening 234, the opening 234having a low point 235. A pump 236 is arranged in a manner to be capableof receiving wetting liquid 237 from the tank 230 and deliver it to alocation in the vicinity of the bottom 238 of the cylindrical body 232.A separator 240, similar to the first and second separators, 144 and168, respectively, shown in FIG. 19, but omitted in FIG. 20, is combinedwith the wetting station 228.

In operation of this type of arrangement, a wetting liquid is added intank 230, and the pump 236 is turned on, so that wetting liquid 237 istaken from the tank 230, and forcefully delivered close to the bottom238 of the hollow cylindrical body 232. This forms a stream of wettingliquid moving in a substantially upward direction and exiting throughthe top 234 to return to the tank 230. More wetting liquid 237 is passedover the low point 235 than over any other higher point of the inclinedopening 234. This produces higher flow in the vicinity of the low point235, so that a yolk allowed to drop into the upward moving stream, iscarried along with the stream and passes over the opening 234 in thevicinity of the low point 235. As the yolk passes over the opening 234it jumps onto the separator 240, where it is separated from the wettingliquid 237.

This type of wetting station, where the yolk falls into a stream ofupward moving wetting liquid may be used for either first wetting liquid(122 containing a cross-linker, for example) or second wetting liquid(166 containing a cross-linkable polymer, for example) or both. Since,however, it works better with higher viscosity liquids, it is preferablethat it is used with the second wetting liquid, which in this particularcase has higher viscosity, and of course in combination with aseparator.

A still different type of wetting station according to the presentinvention is shown in FIGS. 21 and 22. This is a turbulent flow wettingstation 242, comprising an inclined portion 244 provided with a backwall 246, side walls 248, a curvature 250, and an anti-splash wall 252.On top of the inclined portion 244 there is a wetting liquid disposer254, to provide wetting liquid 256, which when coming in contact withthe inclined portion 44 and the walls 246 and 248, forms a turbulentstream 258 with an inclined flow direction. The wetting liquid 256 ispreferably pumped from a tank by similar mechanisms and arrangements asdiscussed in the previous cases. The angle of inclination, orinclination, of the inclined portion 244 is preferably in the range of30 to 70 degrees, more preferably in the range of 45 to 70 degrees, andeven more preferably in the range of 50 to 60 degrees. If the angle issmaller than 30 degrees, the yolk or other article may not slide andstop on the inclined portion 244, while if the angle is larger than 70degrees, an excessive amount of liquid may start taking the samedirection as the initial direction of the yolk or other article leavingthat plate, and in addition, the yolk or other article may starttumbling instead of sliding.

In operation of this wetting station, the wetting liquid is pumpedthrough the dispenser 254, at such rate that it forms a turbulent stream258 with an inclined flow direction when coming in contact with theinclined portion 244 and the walls 246 and 248 of the wetting station242. Due to the turbulence and the inclination of the stream, a yolkdisk 260, falling into the inclined stream 258, is excessively wetted bythe wetting liquid 256, and it jumps to the separator 262 to beseparated from the wetting liquid 256, as already described in detail inthe previous cases.

This type of wetting station, where the yolk falls into a turbulentinclined stream of wetting liquid may be used for either first wettingliquid (122 containing a cross-linker, for example) or second wettingliquid (166 containing a cross-linkable polymer, for example) or both.Since, however, it works better with lower viscosity liquids, it ispreferable that it is used with the first wetting liquid, which in thisparticular case has lower viscosity, and of course in combination with aseparator.

The wetting liquids of the miscellaneous tanks of the disk coatingstation, except for the rinsing tank in a number of occasions, have tobe replenished as they are consumed during the encapsulation process.This could be accomplished by using level switches and a larger sourceof each particular wetting liquid. A good system requiring no levelswitch is illustrated in FIG. 23, wherein a jug 262 with a mouth 278,containing a particular wetting liquid 264 is connected to a tube 266having a valve 268, close to an open end 270 of the tube 266. The openend 270 is positioned at a point determining the desired level of thewetting liquid 264 in the respective tank 272. The open end 270 is theonly opening through which air can pass and enter the jug 264. The jug262 is preferably jacketed and (not shown) so that its contents may bemaintained preferably at a temperature lower than 60° F., and morepreferably in the range of 35°-45° F., as described before regarding themiscellaneous tanks. In addition to the above, a pump 274 is adapted torecirculate the wetting liquid 264 contained in the tank 272, through afilter 276, and maintain the wetting liquid free of solid matter.

In operation of this arrangement, the jug 262 is filled with wettingliquid 264, the tube is installed in its mouth, which may simply closedwith perforated rubber stopper, the valve 268 is turned in a closedposition, and the jug is positioned in a desired position higher thanthe tank 272. The open end 270 of the tube 266 is then positioned at thedesired level, and the valve 268 is turned in the on position. If thelevel of the liquid 264 in the tank 272 is lower than the position ofthe open end 270, air moves into the jug through the open end 270, andwetting liquid exits until the level of the liquid reaches and coversthe open end. At this point, the atmospheric pressure does not allowmore wetting liquid to exit from the jug 262, when the level of thewetting liquid drops under the open end 270, more air enters the jug,and wetting liquid exits the jug 262 until the open end is coveredagain. It is preferred that before positioning the open end 270 at theproper level, the rest of the operation is started, so that all thetubes and additional parts of the station are filled with wettingliquid, and a dynamic level of the wetting liquid in the tank 272 isreached.

After rinsing, the yolk disk enters the packaging station 18 (FIG. 1),which may be any conventional packaging station, well known to the art.The yolk disk and the corresponding amount of egg-white are packagedpreferably in individual portions of one or two eggs per package, theyare then frozen in the freezing station 20 and finally stored in astorage station of freezer 22 for storage and distribution. If theprocess takes place under aseptic conditions, the artificial eggs may bejust refrigerated and stored under refrigeration.

Examples demonstrating the operation of the instant invention have beengiven for illustration purposes only, and should not be construed aslimiting the scope of this invention in any way. In addition it shouldbe stressed that the preferred embodiments discussed in detailhereinabove, as well as any other embodiments encompassed within thelimits of the instant invention, may be practiced individually, or inany combination thereof, according to common sense and/or expertopinion. These combinations also lie within the realm of the presentinvention. Furthermore, any attempted explanations in the discussion areonly speculative and are not intended to narrow the limits of thisinvention.

Composite numerals (containing a number part and a letter part) used inthe different FIGS. represent the same or similar element performing thesame or similar function, if the number part is the same.

What is claimed is:
 1. An apparatus for encapsulating an article with arestrictive barrier comprising:(a) a first liquid wetting station forcontacting the article with an excess of a first liquid, the firstliquid containing a first reactant; (b) a first separator for separatingthe article from the excess of the first liquid; (c) a second liquidwetting station for treating the wetted article with an excess of asecond liquid containing a second reactant, which second reactant reactswith the first reactant to form the restrictive barrier; and (d) asecond separator for separating the treated article from the secondliquid; wherein at least one of the first and second wetting stations isfree of movement during operation, and free of mechanically movingparts.
 2. An apparatus as defined in claim 1, wherein both the first andsecond separators are free of mechanically moving parts.
 3. An apparatusas defined in claim 1, wherein at least one of the first and secondseparators further comprises at least one sliding plate, the slidingplate having a lower curvature and a direction, in a manner that saidarticle, when disposed on the sliding plate, follows a first path awayfrom the curvature in an initial direction substantially parallel to thedirection of the sliding plate, while at least part of the first orsecond liquid, respectively, follows a second path at least partiallycoinciding with the curvature.
 4. An apparatus as defined in claim 3,wherein the sliding plate of at least one of the first and the secondseparators has a first surface tension and an inclination, and the firstor second liquid, respectively, has a second surface tension, the firstsurface tension being higher than the second surface tension, therebycausing the first or second liquid, respectively, to follow the secondpath, and wherein the inclination is adequately high to cause thearticle to follow the first path.
 5. An apparatus as defined in claim 3,wherein at least one of the separators (b) and (d) further comprises agas blower for blowing gas on the article.
 6. An apparatus as defined inclaim 3, wherein at least one of the first and second liquid wettingstations (a) and (c) comprises a liquid dispenser for providing therespective liquid at least partially in a form selected from a groupconsisting of (i) a stream moving in a substantially upward direction,(ii) a stream moving in a substantially horizontal direction, (iii) aturbulent stream with an inclined flow direction, and (iv) a liquidcurtain.
 7. An apparatus as defined in claim 3, wherein at least one ofthe first and second liquid wetting stations (a) and (c) furthercomprises a liquid curtain generator.
 8. An apparatus as defined inclaim 1, wherein:the second wetting station comprisesa liquid dispenserfor providing the second liquid in a form of a stream moving in asubstantially horizontal direction for wetting the article, and a liquidcurtain generator positioned in a manner to wet any part of the articlethat might accidently escape wetting from the liquid stream; and thesecond separator comprises at least one sliding plate, the sliding platehaving a lower curvature and a direction, in a manner that said articlefollows a first path away from the curvature in an initial directionsubstantially parallel to the direction of the sliding plate, while atleast part of the second liquid follows a second path at least partiallycoinciding with the curvature.
 9. An apparatus as defined in claim 8,wherein the second wetting station further comprises a second gas blowerfor blowing a gas on the article.
 10. An apparatus as defined in claim8, wherein the sliding plate has a first surface tension and aninclination, and the second liquid has a second surface tension, thefirst surface tension being higher than the second surface tension,thereby causing the liquid to follow the second path, and wherein theinclination is adequately high to cause the article to follow the firstpath.
 11. An apparatus as defined in claim 8, further comprising:(e) arinsing station comprisinga water dispenser for providing water at leastpartially in a form selected from a group consisting of (i) a streammoving in a substantially upward direction, (ii) a stream moving in asubstantially horizontal direction, (iii) a turbulent stream with aninclined flow direction, for rinsing the article, and a water curtaingenerator positioned in a manner to rinse any part of the article thatmight accidently escape rinsing from the liquid stream; and (f) a waterseparator for separating the water from the article, the separatorcomprising a sliding plate, the sliding plate having a lower curvatureand a direction, in a manner that said article follows a first path awayfrom the curvature in an initial direction substantially parallel to thedirection of the sliding plate, while at least part of the water followsa second path at least partially coinciding with the curvature.